Single module integrated aftertreatment module

A method of filtering an exhaust gas, the method comprising:

• providing a housing having a centerline axis;
• flowing the exhaust gas through a diesel particulate filter disposed within the housing and having a diesel particulate filter center axis aligned with the centerline axis;
• flowing the exhaust gas through a decomposition chamber disposed within the housing downstream of the diesel particulate filter;
• flowing the exhaust gas through a first catalyst member of a selective catalytic reduction catalyst disposed within the housing downstream of the decomposition chamber and having a center axis aligned with the centerline axis;
• flowing the exhaust gas through a second catalyst member of the selective catalytic reduction catalyst after flowing the exhaust gas through the first catalyst member;
• and
• detecting a characteristic of the exhaust gas between the first catalyst member and the second catalyst member using a sensor assembly.

A method of treating an exhaust gas, the method comprising:

• providing a housing having a centerline axis and comprising:
• a first portion having a first diameter;
• a second portion downstream of the first portion and having a second diameter, the second diameter less than the first diameter;
• and
• a third portion downstream of the second portion and having the first diameter;
• flowing the exhaust gas through a diesel particulate filter disposed within the first portion and having a diesel particulate filter center axis aligned with the centerline axis;
• flowing the exhaust gas through a decomposition chamber disposed within the second portion;
• flowing the exhaust gas through a selective catalytic reduction catalyst disposed within the third portion and having a center axis aligned with the centerline axis;
• and
• dosing a reductant into the decomposition chamber using a reductant delivery system.

A method of assembling an exhaust gas aftertreatment system that includes a housing, a diesel particulate filter, a sensor, a selective catalytic reduction catalyst, a decomposition chamber, and a reductant delivery system, the method comprising:

• locating the diesel particulate filter within the housing such that a diesel particulate filter center axis is aligned with a centerline axis of the housing and a first filter of the diesel particulate filter is separated from a second filter of the diesel particulate filter that is located downstream of the first filter;
• causing the sensor to be coupled to the housing between the first filter and the second filter such that the sensor is configured to detect a characteristic of exhaust gas between the first filter and the second filter;
• locating the selective catalytic reduction catalyst within the housing downstream of the diesel particulate filter such that a center axis of the selective catalytic reduction catalyst is aligned with the centerline axis;
• locating the decomposition chamber within the housing downstream of the diesel particulate filter and upstream of the selective catalytic reduction catalyst;
• and
• coupling the reductant delivery system to the decomposition chamber such that the reductant delivery system is configured to dose reductant into the decomposition chamber.

A method of assembling an exhaust gas aftertreatment system that includes a housing, a diesel particulate filter, a sensor assembly, a selective catalytic reduction catalyst, and a decomposition chamber, the method comprising:

• disposing the diesel particulate filter within the housing such that a diesel particulate filter center axis of the diesel particulate filter is aligned with a centerline axis of the housing;
• disposing the selective catalytic reduction catalyst within the housing downstream of the diesel particulate filter such that a center axis of the selective catalytic reduction catalyst is aligned with the centerline axis and a first catalyst member of the selective catalytic reduction catalyst is separated from a second catalyst member of the selective catalytic reduction catalyst downstream of the first catalyst member;
• disposing the sensor assembly within the housing between the first catalyst member and the second catalyst member such that the sensor assembly is configured to detect a characteristic of exhaust gas between the first catalyst member and the second catalyst member;
• and
• disposing the decomposition chamber within the housing downstream of the diesel particulate filter and upstream of the selective catalytic reduction catalyst.

A method of assembling an exhaust gas aftertreatment system that includes a housing, a diesel particulate filter, a sensor assembly, a selective catalytic reduction catalyst, a decomposition chamber, and a reductant delivery system, the method comprising:

• disposing the diesel particulate filter within a first portion of the housing having a first diameter such that a diesel particulate filter center axis of the diesel particulate filter is aligned with a centerline axis of the housing;
• disposing the decomposition chamber disposed within a second portion of the housing having a second diameter that is less that the first diameter and that is disposed downstream of the first portion;
• disposing the selective catalytic reduction catalyst within a third portion of the housing having the first diameter such that a center axis of the selective catalytic reduction catalyst is aligned with the centerline axis;
• and
• coupling the reductant delivery system to the decomposition chamber such that the reductant delivery system is configured to dose reductant into the decomposition chamber.